Method of continuously manufacturing bread



g- 26, 1- J. 'r. DUFFY. JR 27,253,770

' METHOD OF CONTINUOUSLY MANUFACTURING BREAD Filed April 5, 1940 7Sheets-Sheet 1 FE R MENTAT ION CHAM BER 3m entor 73 J. -r. DUFFY, JR.

(Itfomeg 26, 1941- J. r. DUFFY, JR

METHOD OF CONTINUOUSLY MANUFACTURING BREAD 7 Sheets-Sheet 2 Filed- April5, 1940 3nve ntor J. T. D U F FY, J R.

g1 attorney Emmi 3L0 ZOTFJCIZMEEML Aug. 26, 1941. J DUFFY, JR 2,253,770

- METHOD OF CONTINUOUSLY MANUFACTURING BREAD Filed April 5, 1940 7Sheets-Sheet 3 FERMENTAT ION v CHAMBER Snventor J. 'r. DUFFY, JR.

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attorney J. T. DUFFY. JR

Aug. 26, 1 941.

METHOD OF CONTINUOUSLY MANUFACTURING BREAD '7 Sheets-Sheet 4 Filed April5, 1940 [Ill Zhwentor J. T. DUFFY, JR.

attorney us- 26, 1941- J. T. DUFFY, JR 2,253,770

METHOD OF CONTINUOUSLY MANUFACTURING BREAD Filed April 5, 1940 '7Sheets-Sheet 5 3nventor J. T. DUFFY, J R.-

IBH (ittorneg E El Aug. 26, 1941- J. T; DUFFY, JR

METHOD OF commuousm MANUFACTURING BREAD Filed April 5, 1940 7Sheets-Sheet 6 Zmventor attorney a". 'r. DUFFY, JR.

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Aug. 26, l94l. UFF JR 2,253,770

METHOD OF CONTINUOUSLY MANUFACTURING BREAD I Filed. Aplfil 5,- 1940 '7Sheets-Sheet '7 F138 'Fiy. 7

n9 V 77 I ZSnnentor J. 1'. DUFFY, JR.

I v Bu 7 I 5 Wtomeu According to the prose t invention, a

Patented Aug. 26, 1941 METHOD or CONTINUOUSLYMANUFACTUR-' BREAD James T.Duffy, Jr., York, Pa.,' assignor to Read Machinery 00., Inc., York, Pa.,a corporation of ING Pennsylvania Application April 5, 1940, Serial No.327,937

2 Claims.

provide an improved method for the-continuous manufacture of bread inthe formof a strip, in which the dough is handled by automatic machineryfrom the'mixer, through several stages to the oven, and baked.

Another object of the invention is to'provide an improved continuousstrip bread making method in which the dough is worked so as to improvethe texture of the baked bread over bread produced heretofore by knownmethods.-

Other objects, features, and advantages of the present invention will beapparent from the detailed description to follow, .taken. with theaccompanying drawings, in which Figs. 1 to 6 inclusive are diagrammaticviews,

partly in section and partly in elevation, of a continuous breadmanufacturing plant embodying the present invention; Fig. '1 is avertical transverse section taken on the line 1-1 of Fig. 2; r

Fig. 8 is a plan of the structure shown in Fig. 7 showing the operatingmechanism for the adiustable side guides;

' Fig. 9 is a side elevation of the operating mechanism shown in Fig. 8;

- end of. the chamber l5 to the other.

chine may be constructed with a tubular casin having aspiral conveyor orfeeding worm I6 therein mounted on a shaft H which extends through oneend of the housing of said extruding machine and is operated by anysuitable mech-' anism, such as the gear Hi. The gear l8 may beoperatively connected in any desired manner to a suitable source ofpower adapted to impart rotation to the shaft H at the desired rate ofspeed.

As shown in Fig. l the spiral conveyor or worm l6 of the extrudingmachine l3 may be disposed at a vertical angle with respect to theconveyor belt I. .Also the mouth of the-tubular casing of the extrudingmachine l3 which houses the spiral conveyor or worm I6 is unrestricted,so that the strip of dough fed on to the conveyor belt I 4 by theextruding machine will not have a tendency to accumulate at thedischarge end of'the extruding machine but will move readily along withthe conveyor.

The fermentation'chamber I5 is shown in Figs.

1, 2 and 3. This chamber and the conveyor belt ll therein both have alength sufficient to permit the dough to ferment in the desired mannerwhile the strip of dough'is moving from one The purpose of the extrudingmachine I3 is to form the dough in a continuous strip of uniform crosssection, the strip of dough thus formed I being discharged on to theconveyor belt i4.

Fig. 10 is a vertical transverse section taken on the line ll-'-ll ofFig. 3; v

Fig. 11 is a vertical transversesection taken 0ntheline||-Hof1'-'ig.3;

Figs. 12 to 15 inclusive are plan views of dough supporting meanslocated in the steam proofer and the oven, respectively, showing themanner in which the bread'is formed thereon; and

Fig. 16 is a detail plan view of a portionoi the strip'of baked breadshowing the manner in which the same is'formed into'slices.

' batch of unferm'ented bread dough, prepared in the usual manner by amixer II," is discharged from the mixer intothe hopper l2 of anextruding machine l3.

The extruding machine It is adapted to feed the dough in acontinuousistrlp onto the belt ll of a conveyor located in afermentation chamber II, and for'this purpose the extruding madoughisdischarged from-the extruding machine. 1

' The belt. ll may be in the nature of an endless conveyor supported ateach end by suitable pulleys on wheels I9 and 20,- the wheel 20 beingoperatively connected to an electric motor 2| (Fig. 3), or othersuitable source of power,- by

means of a belt or chain 22 mounted, respectively, on pulleysorsprockets 23 and 24 fixed to the motor shaft 25 and to the pulley orwheel shaft 20. The motor 21 is'adapted to operate the belt M .in thedirection of the arrows, Figs. 1, 2 and 3. at the desired speed.Preferably the belt 14 travels at aspeed slightly faster than the speedat which. the dough is discharged from the extruding machine ll, so thatthe strip of dough is pulled or stretched'slightly after the Thefermentation chamber II is in the nature of a housing which isconstructed of'suitable material so as to enclose the conveyor belt.This housing may be built around the discharge end of the extrudingmachine ll, as shown in Fig. 1.

In order that the atmosphere within the chamber if can be controlled.suitable humidity and temperature controls 21 and 28, respectively, are

ring 58.

provided (see Fig. 2). These controls may be operatively connected withthe chamber II by meansof ducts or pipes 29 and 30, as shown in Figs. 1,2 and 3.

At the discharge end of the fermentation chamber l there is a hopper 3|for receiving the fermented dough.

Fromthe hopper 3| the dough is fed to a forming mechanism 32 adapted tosize and shape the dough preparatory to final proofing and baking.

As shown in Fig. 3, the forming mechanism 32 may comprise a divider 33for forming the dough into lumps; and a baller or rounder 34 forimparting the usual kneading operation to the lumps of dough.

The divider 33 may comprise a tubular standard 35 fixed on a suitablesupport or base 36.

Revolvably mounted on the standard 35'is a horizontal circular table 31formed with a series of vertical cylinders 38.

The cylinders 38 are located'adiacent to the periphery of the table 31and each cylinder is open at the top so as to register with the opencontracted bottom of the hopper 3| during operation of the divider.

The bottom of each cylinder is closed by a head 39.

A piston 40 is reciprocably mounted in each cylinder.

A rod 4| extends downwardly from the piston through the head 39.

The lower end of the rod 4| has a roller 42 mounted thereon, said rollerrunning on a cam track 43.

The contour of the cam track 43 is such that The kneading wheel 5| hasan outwardly inclined miter surface 59 and the kneading ring 58 has aninwardly inclined surface 60 so .disposed with respect to the inclinedsurface 59 of the kneading wheel as to afford a constant rolling andkneading on the balls of dough.

At a suitable point the kneading ring 58 is formed with an opening 6|and associated with said opening is a discharge chute 62 adapted todirect the balls of dough on to a conveyor 63.

In the course of their travel through the rounder 34, the rolling andpressure is effected uniformly to all parts of the lumps of dough andthe desired skin is developed on the outer surface thereof.

The conveyor 63 may be in the nature of an endless belt conveyorsupported at each end by suitable pulleys or wheels 64 and 65, the wheel65 being operatively connected to an electric motor or other drivingmeans 66, by means of a belt or chain 61 mounted, respectively, onpulleys or sprockets 68 and 69 fixed to the shaft of said motor and tothe pulley or wheel shaft 10, as showninFig. 2.

The lumps of dough are discharged from the conveyor 63 on to supportingmeans H, which supports the dough while it travels through the finalsteam proofer l3 and oven 14.

Any suitable material may be employed for the dough supporting means 7|.In actual practice, wax paper has proven good for this purpose, sincethe dough will not adhere thereto. The

' wax paper can be delivered froma roll having when a cylinder 38 isdisposed beneath the bottom of the hopper 3| the piston will be disposedin its lowermost position in the cylinder, thereby forming a cavity ofthe desired size, said cavity constituting a dough-measuring chamber.

After the cylinder moves away from the bottom of the hopper 3|, thepiston 40 is moved upwardly in the cylinder 38 by reason of the elevatedportion 44 of the cam track. At one period in the rotation of the table31 the piston '40 will be substantially flush with the top of thecylinder 38 so that the dough which was in the chamber will be ejectedtherefrom and rest on the face of the table 31.

The revolving action of the table 31 carries the lumps of dough againsta stripper which directs the dough towards the rounder 34.

Fixed to the table 3'! and rotatably mounted within the tubular standard35, is a shaft 46 which has mounted on its lower end a gear 41, drivenfrom a suitable source of power supply in any convenient manner.

The rounder 34 comprises a rotatable kneading wheel 5|, the upperportion of which may surround the divider table 31, as shown in Fig.3. 1

Webs or spokes 52 connect the lower portion of the wheel 5| with a hub53 rotatably mounted on the standard 35.

Fixed to the hub 53 is a ring gear 54, the teeth of which are in meshingrelationship with. a pinion 55, driven from a. suitable source of powersupply in any convenient manner.

Surrounding the base 36 is a second base 53 which constitutes a supportfor a frame 51 mounted thereon.

Secured to the frame and arranged in well known manner in the form of aspiral around the rotatable kneading wheel- 5|, is a'kneading scoreslengthwise of the paper. The paper after leaving the roll, passesthrough suitable means.

indicated at I2, Fig. 2; which means are adapted such tubular memberbeing rectangular in cross section. Or any other suitable element may beused for supporting the dough during the proofing and baking steps,inorder to impart to the baked products the desired shape and size.

As shown in Figs. 2, 4 and 5, the steam proofer 13 comprises anelongated structure having insulated walls, top and bottom to provide achamber 16 in which is mounted a conveyor I'I which carries the dough onthesupporting means ll through the steam proofer.

The. conveyor 11 may be in the form of an endless belt conveyorsupported at each end by suitable pulleys or wheels I3 and I9, the wheelI! being operatively connected to an electric motor 44, or other drivingmeans, by means of a belt or chain 3| mounted, respectively, on pulleysor sprockets l2 and 33 fixed to the motor shaft 34 and the shaft 45 ofthe wheel 19, respectively, as shown in Fig. 5.

The conveyor 11 is entirely enclosed by the walls of the steam proofer13, the end of the conveyor having the wheel 1.! being located ad- Inorder that the atmosphere within the steam proofer I3 can be controlled,suitable humidity and temperature controls II and 8!, respectively, areprovided (see Fig. 4). These controls may be operatively connected withthe chamber 16 by means of ducts or pipes I and QI.

The steam'proofer I3 and the oven 14 are connected end to end, but sincethe temperature within the oven 14 is considerably higher than move thehanger Iii towards and away from-the hanger III, the extremities of therods I09 and III which are disposed on the exterior of the structure,each have mounted thereon a gear III and Ill, respectively, as shown inFigs. 8

v and 9, said gears having their teeth in meshing the temperature withinthe steam proofer, a di-- viding wall 92 is constructed, as shown inFig. 5.

The oven I4 comprises an elongated structure having comparatively thickinsulated walls, of well known construction.

Extending into the oven 14 are burners 93 or other means for controllingthe amount of temperature within the oven.

Disposed within the oven I4 is a conveyor in the form of an endless belt94 supported at each end by suitable pulleys or wheels I5 and St, thewheel 96 being operatively connected to an electric motor 91, or otherpower driving means, by means of a belt or chain 98 mounted,respectively, on pulleys or sprockets 99 and I00, fixed to the motorshaft III and the shaft I02 of the wheel 98, respectively, as shown inFig. 6. v

The conveyor 94 is enclosed by the walls of the oven I4, the spacebetween the end of the conveyor having the wheel and the adjacent end ofthe steam proofer conveyor 11 being provided with a horizontallydisposed plate I" which is disposed in substantially the same plane asthe upper horizontal portions of said conveyors so as to support themember II and the dough therein when said member moves from the steamproofer 13 into the oven 14.

For the purpose of supporting the side walls 7 15 of the doughsupporting means ll, stationary side guides I05 and I" are provided.These guides extend the full length of both the steam proofer I3 and theoven 14, from a point adja- -.cent to the member 12 to the oven outletor discharge opening I".

The guides II! and I" are arranged in sub stantially parallelrelationship, said guides being spaced apart a distance equalsubstantially to the width of the bread produced by the process andapparatus.

In order to provide means for adjusting the distance between the guidesI" and I" so that the apparatus can be used for making bread of variouswidths, suitable adjusting mechanism is provided in the means forsupporting the guides.

relationship.

A crank II! is fixed to the ,end of the rod I08. Operation of the crankII! will eifect rotation of the rods ill and III in the oppositedirections,

and since the collars are held by the guides from turning, the hangersIII and II! will be moved in oppomte directions, thereby moving theguides II! and I towards or away from each other depending upon thedirection of rotation imparted to the crank Ill.

From the foregoing it will be understood that I-have provided animproved method of manufacturlng bread continuously. Primarily, themethod and apparatus. is applicable to the manufacture of what is knownas bakers bread, thatv is to say, the product which is composed ofaplurality of slices of uniform thickness and approximately four to fiveinches in width and three and one-half to five inches in height, whichbread is composed of a yeast dough containing flour, salt, sugar,shortening, milk or other liquid, etc.

As shown in Fig. 1, the upper portions of both Figs. 2 and 3, and inFig. 10, the dough is carried in" the form of an unconfined strip on theconveyor l4, at the desired rate of speed to permit the dough toferment, through the fermentation chamber I5.

At the end of the fermentation chamber I5 farthest away from -the mixerII, the fermented dough is fed 'by gravity to the divider 33 and fromthence to the rounder 3A.

The purpose of the divider 33 is to reduce the mass of fermented doughinto lumps of a size which can be accommodated in the rounder 34.

The purpose of the rounder 34 is to work or knead the dough and todevelop a, skin thereon as has been found desirable in the manufactureAt intervals throughout the length of the steam proofer I3 and the ovenI4, pairs of horizontal rods I09 and IIII are mounted in the side wallsof the structure in spaced relation above the conveyors TI and 94.

Depending from the rods I09 are hangers III and-depending from the rodsII. are hangers The lower ends of the hangers III are connected to theguide I", and the lower ends of the hangers II! are connected to theguide I.

The upper portion of the hanger III is formed with an internallythreaded .collar Iii which is mounted on a screw-threaded portion II4 ofthe rod I09.

The upper portion of the hanger I I2 is formed with an internallythreaded collar II! which is mountedon a screw-threaded portion II! ofthe rod 0. I

each lump of dough, the center of the spiral being disposed generallynear the center of each lump or ball of dough, as shown in Fig. 11. The.

action of the rounder 34 also flattens to some extent the pores producedin the dough by the .action of the yeast during the fermentation period.

when the kneaded or worked lumps of dough are discharged from therounder 34, they fall on to the conveyor '3 which is operated at such aspeed as to quickly carry the balls of dough towards the steam prooferI3.

As the conveyor it carries the lumps of dough from the rounder 34towards the steam prooier I3, the lumps gradually flatten out to someextent and may increase slightly in size by the time they enter-thesteam proofer.

Since the lumps of dough are discharged from the'conveyor H on to aconveyor having upstanding side walls, as-the dough moves slowly throughthe steam proofer l3 and the sizeof each lump increases, due to theaction of the yeast, the lumps gradually become elongated, as

shown in Figs. 12 and13, so that by the time the end of the steamproofer I3 is reached, the lumps lose their identity and join end to endto form a continuous strip.

As is well known, it usually requires approximate'l y thirty minutes inorder to properly bake bread. Consequently the length of the oven I4 andthe speed of travel of the conveyor 84 is such as to permit the strip ofdough at any given point toremain in the oven for approximately thirtyminutes.

In Figs. 14 and 15 I have shown the strip of doughas the same appears inthe oven during the baking period. The lines across the strip of doughdenote merely the upper surface marks or creases such as are present inall bread, rolls, etc., formed of more than one lump.

In Eig. 16 I have illustrated the manner in which the baked strip ofdough can be divided transversely in order to provide sliced bread. Anumber of these slices can be bunched together and wrapped in well knownmanner to. provide a loaf of sliced bread. Since the slices are formedtransversely of the baked strip of bread, each loaf will consist ofuniform slices and there will not be any crusts at the ends of the loaf,such as the crusts formed on oaves of pan baked bread.

Having thus descri ed-lny invention, what I claim is:

1. The method of continuous manufacture of bread in the form of a stripwhich comprises pro-' viding a supply of unfermented bread dough,continuously extruding the unfermented dough to form a strip,continuously moving the continuous strip of dough through a controlledatmosphere to cause progressive fermentation of the dough, dividing thestrip of fermented dough into lumps of a predetermined size, mouldingthe individual lumps of dough into ball form with a skin thereover,continuously conveying the lumps of dough through a controlled proofingatmosphere at such a rate of speed that the lumps of dough increase insize to such an' extent as to merge with one another to form acontinuous strip, and then continuously moving the continuous stripthrough a baking atmosphere'and progressively baking said strip withoutdisturbing the continuity thereof.

2. The method of continuous manufacture of bread in the form of a stripwhich comprises providing a supply of unfermented bread dough,continuously extruding the unfermented dough to form a strip.continuouslyv moving the continuous strip of dough through a controlledatmosphere to cause progressive fermentation of the dough, dividing thestrip of fermented dough continuous strip in a straight line through abak ing atmosphere and progressively baking said strip withoutdisturbing the continuity thereof.

JAMES T. DUFFY, JR.

